Fused Deposition Modelling(filament and pellet extrusion processes)

*Times to print the orange juice squeezer by FDM:

About 12 hours (100% fill); Wt about 100gramsBetween 8 to 10 hours (20% fill); Wt about 70 grams

*

Print rate about10-2 kg/hr

T. Gutowski - Limited Distribution 2

Melting (Fe, Al)

Vaporization (Al)

T. Gutowski - Limited Distribution 3

ConventionalMfg Processes

Advanced Machining Processes

Semiconductor Manufacturing

Nano materials

Machine toolimprovement

Junk and Cote 2012

9.4E-03 kg/hr,1.8 to 2.3 E+08 J/kg

Corman 2014

1.2 to 1.8 E-02 kg/hr, 4.1E+07 J/kg to 2.9 E+08

J/kg

EPRI 2014

2.2E-02 kg/hr, 2.8 to 4.0 E+08J/kg

EPRI 2014 , BAAM,

10.0 kg/hr, 4.0E+06 J/kg

Telenko et al. 2011,

2.6E-02 kg/hr, 5.0E+08 J/kgBaumers et al. 2011,

4.1E-01 kg/hr, 2.0E+08 J/kgKellens et al. 2011,

4.1E-02 kg/hr, 1.3E+08 J/kg

Morrow et al. 2005,

3.6E-03kg/hr, 7.7E+09 J/kg

Baumers et al. 2010 ,

1.3E-01 kg/hr, 6.1E+07 J/kg

EPRI 2014,

8.9E-02 kg/hr, 1.1E+08 J/kg

Faludi et al. 2017 Full bed,

1.1E-02 kg/hr, 5.7E+08 J/kg

Faludi et al 2017 Single bed,

4.0E-02 kg/hr,1.2E+09 J/kg

Baumers et al. 2010 Full bed,

5.6E-02 kg/hr,1.1E+08 J/kg

Baumers et al. 2010 Single bed,

4.0E-02 kg/hr, 1.4E+08 J/kg

EPRI 2014

Binder jetting, 6.5E-03 kg/hr, 8.3E+07 J/kg

1.E+05

1.E+06

1.E+07

1.E+08

1.E+09

1.E+10

1.E+11

1.E+12

1.E+13

1.E+14

1.E+15

1.E-06 1.E-05 1.E-04 1.E-03 1.E-02 1.E-01 1.E+00 1.E+01 1.E+02 1.E+03 1.E+04 1.E+05 1.E+06

Ele

ctr

icit

y R

equ

irem

ents

[J/

kg]

Process Rate [kg/hr]

cupola Electric Induction Melting Injection Molding

Machining Finish Machining CVD

Sputtering Grinding Waterjet

Wire EDM Drill EDM Oxidation (Semiconductor)

Material Extrusion: FDM Material Extrusion: BAAM Powder bed fusion: Polymer, laser

Directed energy deposition: DMD Powder bed fusion: Metal, eletron beam Powder bed fusion: Metal, laser

Binder jetting

50 kW 5 kW

500 W

Measured 3D Printing energy intensity (J/kg)Vs Print rate (kg/hr) for AM (metals in red,

plastics in blue) overlaid on conventionalmanufacturing processes.

(Gutowski et al 2017 JIE)

BAAM technologyMore later…

L 2ro

From Lienhard’s bookfor the cooling andheating of cylinders.

For heating use:

𝜃 =𝑇∞ − 𝑇

𝑇∞ − 𝑇𝑖

For length L

ሶ𝑚 = 2𝜋𝑘

𝑐𝐿

Rate Limits on FDM

•Resolution

•Heating

•Grip forceGo, J., Schiffres, S. N., Stevens, A. G., & Hart, A. J. (2017). Rate limits of additive manufacturing by fused filament fabrication and guidelines for high-throughput system design. Additive Manufacturing, 16,

Rate Limits for resolution below 0.5 mm

Big Area Additive Manufacturing (BAAM)Single Screw Extruder

BAAM: longer heating zone, conductivepolymer and bulk heating mechanism

Lonnie Love at Oak RidgeDestructively testingThe BAMM material

Big Area Additive Manufacturing

5 axis machine tool

15

Contains unpublished data – limited distribution

Stratasys Dimension Elite FDM system

Chamber door

User interface

Build chamber

Material cartridges

Extrusion head

Guide rods

Lead screw

Main material cartridge

Support cartridge

Tip cleaning assembly

User interface

Purge container

Build platform

Build Envelope

(XYZ)

8 x 8 x 12 inches (203 x 203 x 305 mm)

Main material ABSplus

Support P400SR (SR-10) - Synthetic thermoplastic polymer

Material

Delivery

One build material canisters 56.3 in³ (923 cm³)

One support material canisters 56.3 in³ (923 cm³)

16

Contains unpublished data – limited distribution

FDM wheel manufacturing steps

CAD STL

FDM printing process Wheels on build sheet

Detaching from base layers Support removal (~4h) Final wheels

Parts in build chamber